Modularized prefabricated distribution transformer rack

Abstract

The utility model discloses a modularized preassembled distribution transformer rack, and relates to the field of transformer racks, the technical scheme is characterized in that the modularized preassembled distribution transformer rack comprises a basic module, an equipment module, a fixing module, a bridge module and a standardized interface, and the modularized preassembled distribution transformer rack has the effects that ground preassembly is realized through the standardized interface, the high-altitude operation risk is effectively reduced, and the working efficiency is improved. All the modules are assembled and debugged in a factory, and only simple splicing and connection need to be performed on site, so that the high-altitude operation time and workload of operators are greatly reduced, the safety risk is reduced, mechanical construction is adopted, manual intervention is reduced, and the efficiency is improved. The hoisting of the basic module, the assembly of the electric pole and the installation of the equipment module are all carried out by adopting professional hoisting machinery, so that the construction efficiency is effectively improved.

Description

Technical Field

[0001] This utility model relates to the field of transformer stands, and more specifically, it relates to a modular prefabricated distribution transformer stand. Background Technology

[0002] In power infrastructure construction, the installation of transformer platforms is a crucial step in building a stable power distribution network. For a long time, traditional transformer platform installation has primarily employed a double-pole mounting method. During construction, the poles must first be erected, after which workers must frequently climb to the poles to perform a series of complex and dangerous operations. They must install various crossarms sequentially, such as high-voltage lead crossarms, surge arrester crossarms, transformer platforms, and integrated distribution box platforms. These crossarms must not only be precisely installed at the designed height but also maintain strict horizontality and be securely connected to the poles. After the crossarm installation is complete, equipment installation work must follow. Throughout the entire installation process, workers are engaged in high-altitude work for extended periods, significantly increasing safety risks.

[0003] Moreover, current standardized test bench designs are mostly based on the traditional concept of "manual labor as the primary method and machinery as a supplement." Under this design philosophy, the modularity of the test bench is low, with components such as iron parts, accessories, cable trays, and equipment being fragmented and scattered. The numerous bolts requiring tightening, and the complex installation of incoming and outgoing lines, have become key factors hindering the smooth progress of mechanized installation. In actual construction, the extensive bolt tightening work not only consumes a lot of time and manpower but is also prone to inconsistent tightening quality due to differences in human operation. Furthermore, the complexity of the incoming and outgoing line installation process makes it difficult to achieve standardization and efficiency, severely restricting the improvement of construction efficiency.

[0004] Therefore, in order to solve the above-mentioned technical problems, this application proposes a modular prefabricated distribution transformer stand. Utility Model Content

[0005] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a modular prefabricated distribution transformer stand.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a modular prefabricated distribution transformer platform, comprising:

[0007] The basic module, which serves as the installation foundation for the utility pole, is precast from concrete, with pre-embedded lifting lugs at the top;

[0008] The equipment module includes a transformer, a distribution box, and a surge arrester, which are each bolted to the crossbeams between poles to form an independent unit.

[0009] The fixing module consists of a clamp assembly with a pin, used to lock the equipment module to the pole;

[0010] A cable tray module, which includes an incoming cable tray and an outgoing cable tray;

[0011] The crossarm module adopts a single-circuit crossarm and is pre-installed with porcelain crossarm and tension insulator hardware string;

[0012] Standardized interfaces ensure that all modules have the same bolt hole specifications, supporting interchangeable installation.

[0013] Preferably, the hoisting earrings of the basic module are symmetrically distributed at its top four corners and are made of Q235 steel.

[0014] Preferably, the bolts of the clamp assembly are subjected to torque in two stages: first, the torque is applied to 30% of the rated torque, and then to 100% of the rated torque.

[0015] Preferably, the crossarm module is vertically sleeved onto the top of the pole by gravity self-locking, and the bottom of the crossarm is provided with an anti-slip rubber pad with a thickness of 5~10mm.

[0016] Preferably, the incoming cable tray and the outgoing cable tray are fixed with bolts.

[0017] Preferably, the basic module is equipped with a laser positioning device and a real-time verticality monitoring system, with a verticality error ≤2°. The real-time verticality monitoring system includes an tilt sensor and a wireless transmission module.

[0018] Preferably, the crossbeams between the poles are provided with reserved mounting holes with a diameter of 16mm and a spacing of 100mm, for adapting to the rotational installation of transformers of different capacities.

[0019] Preferably, the surge arrester is fixed to the crossbeam by an adjustable bracket, the bracket spacing is adjustable from 200 to 500 mm, and the adjustment step is 50 mm.

[0020] Preferably, a shock-absorbing rubber pad is provided between the distribution box module and the crossbeam.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. This utility model achieves pre-assembly on the ground through standardized interfaces, effectively reducing the risks of working at heights. Each module is assembled and debugged in the factory, requiring only simple splicing and connection on site. This significantly reduces the time and workload of workers at heights, lowers safety risks, and utilizes mechanized construction to reduce manual intervention and improve efficiency. From the hoisting of the basic modules and the erection of the poles to the installation of the equipment modules, all operations are carried out using professional lifting machinery, effectively improving construction efficiency and shortening the construction cycle. This addresses the issues in the background technology where workers are exposed to long periods of work at height, greatly increasing safety risks, and the problem of reliance on manual labor.

[0023] 2. This utility model adopts a laser positioning device + real-time verticality monitoring system, which improves the installation accuracy by 40%. During the pole erection process, the position and verticality are monitored and adjusted in real time through the laser positioning device and the real-time verticality monitoring system to ensure that the installation accuracy meets high standards and improves the stability and safety of the platform;

[0024] 3. This utility model avoids stress concentration by applying torque in two stages, thus extending the service life of the equipment. During the tightening of the clamp bolts of the fixing module, a staged torque application method is used, effectively preventing stress concentration, improving the reliability of the equipment connection, and extending the service life of the equipment.

[0025] 4. This utility model avoids stress concentration and extends the service life of the equipment by applying torque in two stages. During the tightening of the clamp bolts of the fixing module, a staged torque application method is used to effectively avoid stress concentration, improve the reliability of the equipment connection, and extend the service life of the equipment. Attached Figure Description

[0026] The accompanying drawings, which are included to provide a further understanding of the present invention and form part of this application, illustrate exemplary embodiments of the present invention and, together with the description thereof, serve to explain the present invention and do not constitute an undue limitation thereof. In the drawings:

[0027] Figure 1 This is a schematic diagram of the specific structure of the basic module in this utility model;

[0028] Figure 2 This is a schematic diagram of the specific structure of the utility pole after the clamp assembly is installed;

[0029] Figure 3 This is a schematic diagram of the specific structure of the basic module and the pole after assembly of this utility model;

[0030] Figure 4 For the present utility model in Figure 3 A schematic diagram showing the specific structure after installing the device module on the basis;

[0031] Figure 5 For the present utility model in Figure 4 A schematic diagram showing the specific structure after installing the cable tray module on the basis;

[0032] Figure 6 For the present utility model in Figure 5 The diagram shows the specific structure after installing the crossarm module on the basis.

[0033] In the diagram: 1. Basic module; 2. Equipment module; 201. Transformer; 202. Distribution box; 3. Pole; 4. Fixing module; 401. Hoop assembly; 5. Cable tray module; 6. Crossarm module. Detailed Implementation

[0034] like Figure 1-6 As shown, this utility model provides a modular prefabricated distribution transformer stand, including the following modules:

[0035] Basic Module 1: A precast concrete foundation is used, with lifting rings precisely embedded in the top of the foundation. The lifting rings are made of high-strength steel, distributed at the four top corners of Basic Module 1, such as Q345B. Their diameter is designed to be 50mm according to the actual load-bearing requirements to ensure sufficient strength and stability, and to safely and reliably withstand the huge tensile forces during subsequent hoisting operations, providing a solid foundation support for the installation of the entire platform.

[0036] Equipment Module 2: The transformer 201, distribution box 202, and surge arrester are respectively installed on specially designed crossbeams (between poles 3). The crossbeams are made of high-quality channel steel treated with hot-dip galvanizing, with a cross-sectional dimension of 250mm × 100mm × 10mm to ensure good load-bearing capacity and corrosion resistance. In this way, independent and complete transformer and distribution box modules are formed. Each module is assembled and debugged in the factory, which greatly improves the efficiency and quality of on-site installation.

[0037] Fixed Module 4: Composed of a clamp assembly 401 with a pin. The clamp assembly 401 is made of high-strength aluminum alloy and precision machined, featuring advantages such as light weight, high strength, and corrosion resistance. The inner diameter of the clamp is customized according to the specifications of the pole 3 to ensure a tight fit with the pole 3, reliably fixing the equipment module 2 and ensuring the stability and safety of the equipment during operation.

[0038] Cable Tray Module 5: Includes incoming and outgoing cable trays. The trays are made of high-strength, flame-retardant fiberglass, featuring lightweight, high strength, corrosion resistance, and excellent insulation. The tray specifications are designed according to actual power transmission needs, ensuring they meet the requirements of different current and voltage levels, providing a safe and reliable channel for power cable laying.

[0039] Crossarm Module 6: A single-circuit crossarm is used, constructed from hot-dip galvanized angle steel with dimensions of ∠80×80×8mm to ensure sufficient strength and stability. A porcelain crossarm and tension insulator hardware string are pre-installed on the crossarm. The porcelain crossarm is made of high-strength ceramic material, offering excellent insulation and mechanical strength. The tension insulator hardware string is made of high-quality steel and hot-dip galvanized, providing corrosion resistance and a long service life. This pre-installation method reduces on-site installation workload and improves installation efficiency and quality.

[0040] Standardized Interfaces: All modules use bolt hole interfaces of uniform specifications. The bolts are made of high-strength stainless steel with a specification of M16×80mm, ensuring good interchangeability and versatility between modules. During the factory production process, the positional and dimensional accuracy of the bolt holes are strictly controlled, with errors controlled within ±0.5mm, to ensure that the modules can be connected quickly and accurately during on-site installation, improving installation efficiency and quality.

[0041] Furthermore, the crossbeams between poles 3 are equipped with pre-drilled mounting holes, each 16mm in diameter and 100mm apart, forming a modular installation grid through evenly distributed holes. This design allows the transformer 201 base to be flexibly fixed to any adjacent hole using U-bolts or custom clamps, adapting to the different installation dimensions of transformers 201 with varying capacities. Rapid rotation installation is possible without modifying the crossarm structure. The 16mm hole diameter matches M14~M16 standard bolts, ensuring connection strength and versatility, meeting the weight-bearing requirements of the transformer 201, and significantly improving the platform's expandability and equipment replacement efficiency. Simultaneously, the surge arrester is fixed to the crossbeam via adjustable brackets. The bracket spacing is adjustable from 200 to 500mm in 50mm increments, allowing for flexible adaptation of the installation position according to the size of different surge arrester models and on-site electrical safety distance requirements, avoiding damage to the crossbeam structure caused by traditional welding or drilling modifications. The 50mm increment design ensures adjustment accuracy (±5mm error) while enabling rapid adjustment via slots or positioning pins. The rapid locking mechanism, with a single adjustment time of ≤2 minutes, significantly improves installation efficiency and allows for future upgrades or expansions of the surge arrester without replacing the bracket, reducing maintenance costs. This fully aligns with the modular platform's "pre-installed and expandable" design philosophy. Furthermore, the shock-absorbing rubber pads between the distribution box module and the crossbeam effectively absorb the mechanical vibrations generated during the operation of the transformer 201 through elastic deformation, reducing the vibration transmission rate by 60%–80%. This prevents bolt loosening or structural fatigue fracture of the electrical components inside the distribution box 202 due to long-term vibration. Simultaneously, the weather-resistant design of the rubber pads ensures long-term stable operation in harsh outdoor environments. Combined with the modular pre-installed structure, this achieves "stress-free" installation of the distribution box 202, extending equipment lifespan and reducing noise pollution caused by vibration, meeting the dual requirements of mechanized construction for equipment reliability and environmental friendliness.

[0042] The installation steps for the power distribution transformer stand of this utility model are as follows:

[0043] Step 1: Pre-assembly of modular components (warehouse or on-site)

[0044] On the ground, the clamp assembly 401 of the fixing module 4 is connected to the low-voltage crossarm using high-strength bolts. The tightening torque of the bolts is controlled between 80 N·m and 100 N·m to ensure a firm and reliable connection. The frame structure is then constructed and installed on the pole 3.

[0045] Using a truck-mounted crane, the transformer 201, distribution box 202, and surge arrester are placed on the crossbeam between two poles 3, and then connected and fixed with matching bolts to form a complete equipment module 2.

[0046] Install the porcelain crossarm and tension insulator hardware string on the crossarm. During the installation process, strictly follow the design requirements to ensure that the porcelain crossarm and tension insulator hardware string are installed in the correct positions, forming a standard crossarm module 6.

[0047] Use an electric wrench to tighten all connecting bolts to the specified torque value to ensure the stability of the entire pre-assembled structure. At the same time, conduct a comprehensive inspection of the pre-assembled components, including the tightness of bolts, the connection of parts, and the verticality and horizontality of the overall structure, to ensure that the pre-assembly quality meets the requirements.

[0048] Step 2: Basic on-site preparation

[0049] Based on the terrain conditions, specialized excavation equipment was used to excavate the foundation pit. The dimensions of the foundation pit were determined according to the design requirements, with the depth error controlled within ±50mm and the bottom flatness error controlled within ±20mm. After excavation, compaction equipment was used to compact the bottom of the foundation pit to ensure that the soil density at the bottom met the design requirements, providing a stable foundation for the installation of prefabricated foundation module 1.

[0050] Precast foundation module 1 was placed, and during placement, a high-precision level was used for calibration to ensure that the levelness error of the precast foundation module 1 was controlled within ±2mm / m. After calibration, high-strength concrete was poured to fix the precast foundation module 1. The concrete strength grade was selected as C30 or higher according to design requirements. During the pouring process, the density and pouring quality of the concrete were ensured to provide a solid foundation support for the subsequent hoisting of the overall frame.

[0051] Step 3: Overall frame hoisting

[0052] The lifting lugs on top of the precast foundation module 1 are connected using crane hooks. These lugs are made of Q345B high-strength steel, and their load-bearing capacity has been rigorously calculated and tested to ensure they can safely and reliably support the weight of the precast foundation. The precast foundation is then accurately placed into the pit, with real-time monitoring using measuring instruments to ensure that the positional deviation is controlled within ±50mm.

[0053] The pole 3 is vertically hoisted onto the foundation module 1 using an integrated pole erecting machine. During the hoisting process, the verticality of the pole 3 is adjusted in real time using a laser positioning device to ensure that the error is ≤2°. A real-time verticality monitoring system is also used, which consists of an inclination sensor and a wireless transmission module. The inclination sensor detects the tilt angle (X / Y axis direction) of the pole in real time during the hoisting process and converts the data into an electrical signal through high-precision measurement (±0.1°). The wireless transmission module (such as Bluetooth or LoRa) sends the angle data to the ground control terminal in real time. Based on the feedback of the verticality deviation (such as "current tilt 3.2°"), the operator manipulates the hydraulic mechanism of the integrated pole erecting machine to adjust the pole's posture until the verticality error is ≤2°. The final data is recorded by the wireless module for construction acceptance, realizing full-process mechanized and precise control of "detection-transmission-adjustment-fixing".

[0054] The pole 3 is fixed to the foundation module 1 by pouring fine aggregate concrete. The strength grade of the fine aggregate concrete is C35 or above. During the pouring process, the density and pouring quality of the concrete are ensured so that the pole 3 and the foundation module 1 form a solid whole, ensuring the stability and safety of the entire platform.

[0055] Step 4: Modular hoisting

[0056] Hoist the distribution box module into place and lock it in place using the clamp assembly 401 of the fixing module 4. The insertion depth of the pin of the clamp assembly 401 should not be less than 50mm to ensure a firm and reliable connection. During the locking process, use a torque wrench to tighten the clamp bolts to ensure that the tightening torque of the bolts reaches the specified value.

[0057] The transformer module is hoisted into place and locked using the clamp assembly 401 of the fixing module 4, with the same operating requirements as the distribution box module. The clamp bolts are tightened in two stages: first, pre-tightening to 30% torque, and then symmetrically loading to 100% torque (80~100 N·m). This staged torque control method effectively avoids stress concentration and extends the service life of the equipment.

[0058] The incoming and outgoing cable trays are hoisted into place and secured with matching bolts. The tightening torque of the bolts is controlled between 60 N·m and 80 N·m to ensure that the cable trays are firmly installed and reliably connected, providing a safe and stable passage for the laying of power cables.

[0059] The crossarm module 6 is vertically hoisted and inserted into the pole 3 from the pole head. It is fixed by the weight of the crossarm itself and the anti-slip rubber pad (5-10mm thick) set at the bottom of the crossarm, ensuring the stability and accuracy of the crossarm installation.

[0060] Step 5: Installation of low-voltage outgoing lines and medium-voltage incoming lines

[0061] Workers climbed the pole to install the low-voltage outgoing lines and medium-voltage incoming lines. Before climbing, workers conducted a comprehensive inspection of the climbing equipment and safety gear to ensure they were in good working order and reliable. During installation, they strictly followed electrical installation specifications to ensure secure wiring, good insulation, and safe and stable power transmission.

[0062] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model in any way. Those skilled in the art can readily implement this utility model based on the accompanying drawings and the above description. However, any modifications, alterations, or equivalent variations made by those skilled in the art without departing from the scope of the utility model's technical solution, utilizing the disclosed technical content, are considered equivalent embodiments of this utility model. Furthermore, any equivalent changes, alterations, or variations made to the above embodiments based on the essential technology of this utility model are still within the protection scope of this utility model's technical solution.

Claims

1. A modular prefabricated distribution transformer stand, characterized in that: include: The basic module (1), which serves as the installation foundation for the pole (3), is made of precast concrete and has a pre-embedded hoisting ear on the top; The equipment module (2) includes a transformer (201), a distribution box (202), and a surge arrester. The three are respectively fixed to the crossbeams between poles (3) by bolts to form independent units, thereby forming an independent transformer module and distribution box module. The fixing module (4) consists of a clamp assembly (401) with a pin, used to lock the equipment module (2) to the pole (3); The cable tray module (5) includes an incoming cable tray and an outgoing cable tray; The crossarm module (6) adopts a single-circuit crossarm and is pre-installed with porcelain crossarm and tension insulator hardware string; Standardized interfaces ensure that all modules have the same bolt hole specifications, supporting interchangeable installation.

2. The modular prefabricated distribution transformer stand according to claim 1, characterized in that: The hoisting earrings of the basic module (1) are symmetrically distributed at the four corners of its top, and are made of Q235 steel.

3. A modular prefabricated distribution transformer platform according to claim 1, characterized in that: The bolts of the clamp assembly (401) are loaded with torque in two stages: first, to 30% of the rated torque, and then to 100% of the rated torque.

4. A modular prefabricated distribution transformer stand according to claim 1, characterized in that: The crossarm module (6) is vertically sleeved to the top of the pole (3) by gravity self-locking. The bottom of the crossarm is provided with an anti-slip rubber pad with a thickness of 5-10mm.

5. A modular prefabricated distribution transformer stand according to claim 1, characterized in that: The incoming and outgoing cable trays in the cable tray module (5) are fixed with bolts.

6. A modular prefabricated distribution transformer platform according to claim 1, characterized in that: When the basic module (1) installs the pole (3), it uses a laser positioning instrument and a real-time verticality monitoring system. The verticality error is ≤2°. The monitoring system includes an inclination sensor and a wireless transmission module.

7. A modular prefabricated distribution transformer stand according to claim 1, characterized in that: The crossbeams between the poles (3) are provided with reserved installation holes with a diameter of 16mm and a spacing of 100mm, which are used to adapt to the rotation installation of transformers (201) of different capacities.

8. A modular prefabricated distribution transformer stand according to claim 1, characterized in that: The surge arrester is fixed to the crossbeam between the poles (3) by an adjustable bracket. The bracket spacing is adjustable from 200 to 500 mm, and the adjustment step is 50 mm.

9. A modular prefabricated distribution transformer stand according to claim 1, characterized in that: The distribution box module is equipped with shock-absorbing rubber pads between itself and the crossbeam.

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